Systems and methods for cracking hydrocarbon streams such as crude oils utilizing catalysts which include zeolite mixtures

ABSTRACT

A hydrocarbon feed stream may be cracked by a method including contacting the hydrocarbon feed stream with a cracking catalyst in a reactor unit. The hydrocarbon feed stream has an API gravity of at least 40 degrees. The cracking catalyst may include one or more binder materials, one or more matrix materials, *BEA framework type zeolite, FAU framework type zeolite, and MFI framework type zeolite.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationSer. 62/462,689 filed Feb. 23, 2017 which is incorporated by referenceherein in its entirety.

BACKGROUND Field

The present disclosure relates to the cracking of hydrocarbons, and moreparticularly to systems and method for the cracking of hydrocarbonstreams by zeolite-containing catalyst systems.

Technical Background

Light olefins such as ethylene, propylene, and butene are basicintermediates for a large portion of the petrochemical industry. Theyare mainly obtained through the thermal cracking (sometimes referred toas “steam pyrolysis” or “steam cracking”) of petroleum gases anddistillates such as naphtha, kerosene, or even gas oil. However, asdemands rise for these basic intermediate compounds, other productionsources must be considered beyond traditional thermal cracking processesutilizing petroleum gases and distillates as feedstocks.

These intermediate compounds may also be produced through refineryfluidized catalytic cracking (FCC) processes, where heavy feedstockssuch as gas oils or residues are converted. For example, an importantsource for propylene production is refinery propylene from the crackingof distillate feedstocks such as gas oils or residues. However, thesefeedstocks are usually limited and result from several costly and energyintensive processing steps within a refinery.

BRIEF SUMMARY

Accordingly, in view of the ever growing demand of these intermediarypetrochemical products such as butene, there is a need for processes andcatalyst systems to produce these intermediate compounds from othertypes of feedstock materials, such as relatively light crude oilsupplies like gas condensate. For example, there is a need for catalystsand processes for converting gas condensate crude feedstock. Accordingto one embodiment, the present disclosure is related to processes andcracking catalysts for producing these intermediate compounds such aslight olefins, sometimes referred to in this disclosure as “systemproducts,” by the direct conversion of feedstock crude oils such as gascondensate. For example, production of light olefins from lighthydrocarbon feedstocks, such as gas condensate, may be beneficial ascompared with the conversion of other feedstocks in producing theseintermediate compounds because the light hydrocarbon feedstocks may bemore widely available, may involve less processing costs to convert tolight olefins, or both. However, new cracking catalysts are needed toselectively convert light hydrocarbon feedstocks to products withrelatively high yields of light olefins such as butene.

According to one or more embodiments, a hydrocarbon feed stream may becracked by a method comprising contacting the hydrocarbon feed streamwith a cracking catalyst in a reactor unit. The hydrocarbon feed streamhas an API gravity of at least 40 degrees. The cracking catalyst mayinclude one or more binder materials in an amount of from 5 weightpercent (wt. %) to 30 wt. % of the total cracking catalyst, one or morematrix materials in an amount of from 30 wt. % to 60 wt. % of the totalcracking catalyst, *BEA framework type zeolite in an amount of from 5wt. % to 45 wt. % of the total cracking catalyst, FAU framework typezeolite in an amount of from 5 wt. % to 45 wt. % of the total crackingcatalyst, and MFI framework type zeolite in an amount of from 5 wt. % to45 wt. % of the total cracking catalyst.

According to another embodiment, a hydrocarbon feed stream may becracked by a method comprising contacting the hydrocarbon feed streamwith a cracking catalyst in a reactor unit. The hydrocarbon feed streamhas an API gravity of at least 40 degrees. The cracking catalyst maycomprise pseudoboehmite in an amount of from 5 wt. % to 30 wt. % of thetotal cracking catalyst, kaolin in an amount of from 30 wt. % to 60 wt.% of the total cracking catalyst, zeolite Beta in an amount of from 5wt. % to 45 wt. % of the total cracking catalyst, zeolite Y in an amountof from 5 wt. % to 45 wt. % of the total cracking catalyst, and ZSM-5 inan amount of from 5 wt. % to 45 wt. % of the total cracking catalyst.

According to yet another embodiment, a system for cracking a hydrocarbonfeed stream may comprise a reactor, a hydrocarbon feed stream enteringthe reactor, where the hydrocarbon feed stream has an API gravity of atleast 40 degrees, a product stream exiting the reactor, and a crackingcatalyst positioned at least in the reactor, where the cracking catalystcomprises. The cracking catalyst may include one or more bindermaterials in an amount of from 5 weight percent (wt. %) to 30 wt. % ofthe total cracking catalyst, one or more matrix materials in an amountof from 30 wt. % to 60 wt. % of the total cracking catalyst, *BEAframework type zeolite in an amount of from 5 wt. % to 45 wt. % of thetotal cracking catalyst, FAU framework type zeolite in an amount of from5 wt. % to 45 wt. % of the total cracking catalyst, and MFI frameworktype zeolite in an amount of from 5 wt. % to 45 wt. % of the totalcracking catalyst.

Additional features and advantages of the technology described in thisdisclosure will be set forth in the detailed description which follows,and in part will be readily apparent to those skilled in the art fromthe description or recognized by practicing the technology as describedin this disclosure, including the detailed description which follows,the claims, as well as the appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description of specific embodiments of thepresent disclosure can be best understood when read in conjunction withthe following drawings, where like structure is indicated with likereference numerals and in which:

FIG. 1 depicts a generalized schematic diagram of an embodiment of afluid catalytic cracking reactor unit, according to one or moreembodiments described in this disclosure; and

FIG. 2 depicts boiling point data for an example gas condensatefeedstock, according to one or more embodiments described in thisdisclosure.

For the purpose of describing the simplified schematic illustrations anddescriptions of FIG. 1, the numerous valves, temperature sensors,electronic controllers and the like that may be employed and well knownto those of ordinary skill in the art of certain chemical processingoperations are not included. Further, accompanying components that areoften included in conventional chemical processing operations, such asrefineries, such as, for example, air supplies, catalyst hoppers, andflue gas handling are not depicted. It should be understood that thesecomponents are within the spirit and scope of the present embodimentsdisclosed. However, operational components, such as those described inthe present disclosure, may be added to the embodiments described inthis disclosure.

It should further be noted that arrows in the drawings refer to processstreams. However, the arrows may equivalently refer to transfer lineswhich may serve to transfer process steams between two or more systemcomponents. Additionally, arrows that connect to system componentsdefine inlets or outlets in each given system component. The arrowdirection corresponds generally with the major direction of movement ofthe materials of the stream contained within the physical transfer linesignified by the arrow. Furthermore, arrows which do not connect two ormore system components signify a product stream which exits the depictedsystem or a system inlet stream which enters the depicted system.Product streams may be further processed in accompanying chemicalprocessing systems or may be commercialized as end products. Systeminlet streams may be streams transferred from accompanying chemicalprocessing systems or may be non-processed feedstock streams.

Additionally, arrows in the drawings may schematically depict processsteps of transporting a stream from one system component to anothersystem component. For example, an arrow from one system componentpointing to another system component may represent “passing” a systemcomponent effluent to another system component, which may include thecontents of a process stream “exiting” or being “removed” from onesystem component and “introducing” the contents of that product streamto another system component.

Reference will now be made in greater detail to various embodiments,some embodiments of which are illustrated in the accompanying drawings.Whenever possible, the same reference numerals will be used throughoutthe drawings to refer to the same or similar parts.

DETAILED DESCRIPTION

Described in this disclosure are various embodiments of systems andmethods for processing hydrocarbon feed streams, such as light crudeoils, into petrochemical products such as streams that include one ormore of ethylene, propylene, and butene. Generally, the processing ofthe hydrocarbon feed stream may include cracking of the hydrocarbon feedstream by contacting the hydrocarbon feed stream with a crackingcatalyst. According to one or more embodiments, the hydrocarbon feedstream may comprise a relatively light crude oil, such as gascondensate. According to one or more embodiments, the cracking catalystmay include a zeolite mixture comprising a *BEA framework type zeolite(such as, but not limited to, zeolite Beta), an FAU framework typezeolite (such as, but not limited to, zeolite Y), and an MFI frameworktype zeolite (such as, but not limited to, ZSM-5). It should beunderstood that *BEA, MFI, and FAU refer to zeolite framework types asidentified by their respective three letter codes established by theInternational Union of Pure and Applied Chemistry (IUPAC). In additionto the zeolite mixture, the cracking catalyst may comprise othermaterials, such as, without limitation, one or more alumina-containingmaterials, one or more binder materials, or both. The cracking catalystconverts the hydrocarbon feed stream into a product stream that mayinclude, without limitation, dry gases (that is, one or more of hydrogengas, methane, and ethane), liquefied petroleum gases (that is, one ormore of propane and butane), light olefins (that is, one or more ofethylene, propylene, and butene), gasoline (that is, hydrocarbons having4 to 12 carbons per molecule, including alkanes, cycloalkanes, andolefins), and coke. It should be understood that not all hydrocarbons ofthe feed stream are cracked by the cracking catalyst and, generally,mostly heavier components of the feed are cracked.

According to some embodiments described in the present disclosure, thehydrocarbon feed stream which is converted to the product stream bycontact with the cracking catalyst may include, consist essentially of,or entirely consist of a relatively light crude oil. For example, thehydrocarbon feed stream may have a relatively great American PetroleumInstitute (API) gravity. For example, the API gravity of the hydrocarbonfeed stream may be at least 30 degrees, at least 40 degrees, or even atleast 50 degrees. For example, in one embodiment, the hydrocarbon feedstream comprises or consists of gas condensate having an API gravity offrom 50 degrees to 55 degrees. As described in the present disclosure,“crude oil” refers to fuels which have been minimally processed or notprocessed following extraction from their respective sources. Forexample, gas condensate is considered a crude oil even though it mayundergo minimal processing to separate vapor fractions from liquidfractions in the formation of the gas condensate. Additionally, crudeoils may include hydrocarbon feedstocks which have been minimallyprocessed such as by the partial or full removal of unwantedcontaminants such as one or more of sulfur, heavy metals, nitrogen, oraromatics, such as by hydroprocessing. Additionally, it should beunderstood that while some embodiments presently described are relatedto the cracking of crude oil feedstocks, other embodiments may bedirected to the cracking of fractions of crude oil feedstocks orpartially refined hydrocarbon feedstocks.

Without being bound by theory, it is believed that the combination ofzeolites in the zeolite mixture (that is, the combination of *BEAframework type zeolite, FAU framework type zeolite, and MFI frameworktype zeolite, for example, a zeolite mixture including zeolite Beta,zeolite Y, and ZSM-5) promotes conversion of the hydrocarbon feed streamto a product stream having an enhanced yield of light olefins. Forexample, the utilization of zeolite Beta in combination with zeolite Yand ZSM-5 may promote the formation of light olefins from a hydrocarbonfeedstock that is relatively light, such as gas condensate. Withoutbeing bound by theory, it is believed that in order to increase thelight olefin yield, gasoline octane number, or both, it may beadvantageous to use a catalyst composition containing a large porezeolite, such as an FAU framework type zeolite or *BEA framework typezeolite as the primary cracking component in addition to a medium porezeolite such as MFI framework type zeolite. For example, zeolite Y maybe utilized for the production of gasoline, while ZSM-5 may be utilizedto increase the yield of propylene and the octane number. Zeolite Betamay be utilized to produce olefins and the octane number of gasoline. Byhaving these zeolites in one catalyst formulation, a petrochemical FCC(fluid catalytic cracking) catalyst system that results in a significantincrease in light olefin yield and gasoline octane from relatively lightfeedstock fuels may be obtained.

As used in this disclosure, a “cracking catalyst” refers to anysubstance which increases the rate of a cracking chemical reaction. Asused in this disclosure, “cracking” generally refers to a chemicalreaction where a molecule having carbon to carbon bonds is broken intomore than one molecule by the breaking of one or more of the carbon tocarbon bonds, or is converted from a compound which includes a cyclicmoiety, such as an aromatic, to a compound which does not include acyclic moiety or contains fewer cyclic moieties than prior to cracking.However, while cracking catalysts promote cracking of a reactant, thecracking catalyst is not limited to cracking functionality, and may, insome embodiments, be operable to promote other reactions.

In one or more embodiments, the catalyst composition may comprise an FAUframework type zeolite, such as zeolite Y. As used herein, “zeolite Y”refers to zeolite having a FAU framework type according to the IUPACzeolite nomenclature and consisting of silica and alumina, where themolar ratio of silica to alumina is at least 3. For example, the molarratio of silica to alumina in the zeolite Y may be at least 5, at least12, or even at least 30, such as from 5 to 30, from 12 to 30, or fromabout 15 to about 30. The unit cell size of the zeolite Y may be fromabout 24 Angstrom to about 25 Angstrom, such as 24.56 Angstrom.

According to one or more embodiments, the cracking catalyst may comprisean amount of FAU framework type zeolite (such as zeolite Y) in an amountof from 5 wt. % to 45 wt. % of the total cracking catalyst. For example,according to embodiments, the cracking catalyst may comprise FAUframework type zeolite in an amount of from 5 wt. % to 40 wt. % of thetotal cracking catalyst, from 5 wt. % to 35 wt. % of the total crackingcatalyst, from 5 wt. % to 30 wt. % of the total cracking catalyst, from5 wt. % to 25 wt. % of the total cracking catalyst, from 5 wt. % to 20wt. % of the total cracking catalyst, from 5 wt. % to 15 wt. % of thetotal cracking catalyst, from 5 wt. % to 10 wt. % of the total crackingcatalyst, from 10 wt. % to 45 wt. % of the total cracking catalyst, from15 wt. % to 45 wt. % of the total cracking catalyst, from 20 wt. % to 45wt. % of the total cracking catalyst, from 25 wt. % to 45 wt. % of thetotal cracking catalyst, from 30 wt. % to 45 wt. % of the total crackingcatalyst, from 35 wt. % to 45 wt. % of the total cracking catalyst, orfrom 40 wt. % to 45 wt. % of the total cracking catalyst. According toadditional embodiments, the cracking catalyst may comprise FAU frameworktype zeolite in an amount of from 10 wt. % to 20 wt. % of the totalcracking catalyst, from 15 wt. % to 30 wt. % of the total crackingcatalyst, or from 10 wt. % to 40 wt. % of the total cracking catalyst.In one or more embodiments, all or a portion of the FAU framework typezeolite may be zeolite Y.

In one or more embodiments, the cracking catalyst may comprise a *BEAframework type zeolite, such as zeolite Beta. As used in thisdisclosure, “zeolite Beta” refers to zeolite having a *BEA frameworktype according to the IUPAC zeolite nomenclature and consisting ofsilica and alumina. The molar ratio of silica to alumina in the zeoliteBeta may be at least 10, at least 25, or even at least 100. For example,the molar ratio of silica to alumina in the zeolite Beta may be from 5to 500, such as from 25 to 300. The zeolite Beta may be in the form ofH-Beta, the acidic form of zeolite Beta usually derived from NH₄-Betavia calcination. In one or more embodiments, the zeolite Beta may bestabilized by direct reaction with phosphoric acid (H₃PO₄) or byimpregnation with ammonium hydrogen phosphate (NH₄)₂HPO₄.

According to one or more embodiments, the *BEA framework type zeolitemay comprise one or more phosphorous-containing compounds, such as aphosphorous oxide, such as phosphorous pentoxide (“P₂O₅”). For example,the *BEA framework type zeolite may include one or morephosphorous-containing compounds in an amount of from 1 wt. % to 20 wt.% of the total amount of the *BEA framework type zeolite, such as from 5wt. % to 10 wt. % of the total amount of *BEA framework type zeolite.According to additional embodiments, the amount ofphosphorous-containing compounds relative to the total amount of *BEAframework type zeolite may be from 1 wt. % to 18 wt. %, from 1 wt. % to16 wt. %, from 1 wt. % to 14 wt. %, from 1 wt. % to 12 wt. %, from 1 wt.% to 10 wt. %, from 1 wt. % to 8 wt. %, from 1 wt. % to 6 wt. %, from 1wt. % to 4 wt. %, from 1 wt. % to 2 wt. %, from 2 wt. % to 20 wt. %,from 4 wt. % to 20 wt. %, from 6 wt. % to 20 wt. %, from 8 wt. % to 20wt. %, from 10 wt. % to 20 wt. %, from 12 wt. % to 20 wt. %, from 14 wt.% to 20 wt. %, from 16 wt. % to 20 wt. %, or from 18 wt. % to 20 wt. %.

According to one or more embodiments, the cracking catalyst may comprisean amount of *BEA framework type zeolite (such as zeolite Beta) in anamount of from 5 wt. % to 45 wt. % of the total cracking catalyst. Forexample, according to embodiments, the cracking catalyst may comprise*BEA framework type zeolite in an amount of from 5 wt. % to 40 wt. % ofthe total cracking catalyst, from 5 wt. % to 35 wt. % of the totalcracking catalyst, from 5 wt. % to 30 wt. % of the total crackingcatalyst, from 5 wt. % to 25 wt. % of the total cracking catalyst, from5 wt. % to 20 wt. % of the total cracking catalyst, from 5 wt. % to 15wt. % of the total cracking catalyst, from 5 wt. % to 10 wt. % of thetotal cracking catalyst, from 10 wt. % to 45 wt. % of the total crackingcatalyst, from 15 wt. % to 45 wt. % of the total cracking catalyst, from20 wt. % to 45 wt. % of the total cracking catalyst, from 25 wt. % to 45wt. % of the total cracking catalyst, from 30 wt. % to 45 wt. % of thetotal cracking catalyst, from 35 wt. % to 45 wt. % of the total crackingcatalyst, or from 40 wt. % to 45 wt. % of the total cracking catalyst.According to additional embodiments, the cracking catalyst may comprise*BEA framework type zeolite in an amount of from 5 wt. % to 35 wt. % ofthe total cracking catalyst, from 15 wt. % to 35 wt. % of the totalcracking catalyst, from 20 wt. % to 35 wt. % of the total crackingcatalyst, or from 25 wt. % to 40 wt. % of the total cracking catalyst.

In one or more embodiments, the catalyst composition may comprise MFIframework type zeolite, such as ZSM-5. As used in this disclosure,“ZSM-5” refers to zeolites having an MFI framework type according to theIUPAC zeolite nomenclature and consisting of silica and alumina. ZSM-5refers to “Zeolite Socony Mobil-5” and is a pentasil family zeolite thatcan be represented by the chemical formulaNa_(n)Al_(n)Si_(96−n)O₁₉₂.16H₂O, where 0<n<27. According to one or moreembodiments, the molar ratio of silica to alumina in the ZSM-5 may be atleast 5. For example, the molar ratio of silica to alumina in thezeolite Y may be at least 10, at least 12, or even at least 30, such asfrom 5 to 30, from 12 to 30, or from 5 to 80. Examples of suitable ZSM-5include those commercially available from Zeolyst International, such asCBV2314, CBV3024E, CBV5524G, and CBV28014.

According to one or more embodiments, the MFI framework type zeolite maycomprise one or more phosphorous-containing compounds, such as aphosphorous oxide, such as phosphorous pentoxide (“P₂O₅”). For example,the MFI framework type zeolite may include one or morephosphorous-containing compounds in an amount of from 1 wt. % to 20 wt.% of the total amount of MFI framework type zeolite, such as from 5 wt.% to 10 wt. % of the total amount of MFI framework type zeolite.According to additional embodiments, the amount of phosphorouscontaining compounds relative to the total amount of MFI framework typezeolite may be from 1 wt. % to 18 wt. %, from 1 wt. % to 16 wt. %, from1 wt. % to 14 wt. %, from 1 wt. % to 12 wt. %, from 1 wt. % to 10 wt. %,from 1 wt. % to 8 wt. %, from 1 wt. % to 6 wt. %, from 1 wt. % to 4 wt.%, from 1 wt. % to 2 wt. %, from 2 wt. % to 20 wt. %, from 4 wt. % to 20wt. %, from 6 wt. % to 20 wt. %, from 8 wt. % to 20 wt. %, from 10 wt. %to 20 wt. %, from 12 wt. % to 20 wt. %, from 14 wt. % to 20 wt. %, from16 wt. % to 20 wt. %, or from 18 wt. % to 20 wt. %.

According to one or more embodiments, the cracking catalyst may compriseMFI framework type zeolite, such as ZSM-5, in an amount of from 5 wt. %to 45 wt. % of the total cracking catalyst. For example, according toembodiments, the cracking catalyst may comprise MFI framework typezeolite in an amount of from 5 wt. % to 40 wt. % of the total crackingcatalyst, from 5 wt. % to 35 wt. % of the total cracking catalyst, from5 wt. % to 30 wt. % of the total cracking catalyst, from 5 wt. % to 25wt. % of the total cracking catalyst, from 5 wt. % to 20 wt. % of thetotal cracking catalyst, from 5 wt. % to 15 wt. % of the total crackingcatalyst, from 5 wt. % to 10 wt. % of the total cracking catalyst, from10 wt. % to 45 wt. % of the total cracking catalyst, from 15 wt. % to 45wt. % of the total cracking catalyst, from 20 wt. % to 45 wt. % of thetotal cracking catalyst, from 25 wt. % to 45 wt. % of the total crackingcatalyst, from 30 wt. % to 45 wt. % of the total cracking catalyst, from35 wt. % to 45 wt. % of the total cracking catalyst, or from 40 wt. % to45 wt. % of the total cracking catalyst. According to additionalembodiments, the cracking catalyst may comprise MFI framework typezeolite in an amount of from 10 wt. % to 30 wt. % of the total crackingcatalyst, from 10 wt. % to 20 wt. % of the total cracking catalyst, from5 wt. % to 10 wt. % of the total cracking catalyst, or from 10 wt. % to25 wt. % of the total cracking catalyst.

According to one or more embodiments, one or more of the MFI frameworktype zeolite, *BEA framework type zeolite, and FAU framework typezeolite may be substantially free of transition metals (that is,comprises less than 1 wt. % of transition metal). For example, one ormore of the ZSM-5, zeolite Beta, and zeolite Y may consist of less thanor equal to 1 wt. %, 0.5 wt. %, 0.3 wt. %, 0.1 wt. %, 0.01, or even0.001 wt. % of transition metals. As described in this disclosure,transition metals include scandium, titanium, vanadium, chromium,manganese, iron, cobalt, nickel, copper, zinc, yttrium, zirconium,niobium, molybdenum, technetium, ruthenium, rhodium, palladium, silver,cadmium, hafnium, tantalum, tungsten, rhenium, osmium, iridium,platinum, gold, mercury, rutherfordium, dubnium, seaborgium, bohrium,hassium, meitnerium, darmstadtium, roentgenium, and copernicium.

In one or more embodiments, the catalyst composition may comprise one ormore binder materials, such as alumina-containing compounds orsilica-containing compounds (including compounds containing alumina andsilica). As used in this disclosure, “binder materials” refer tomaterials which may serve to “glue” or otherwise hold zeolite and thematrix together in the microsphere. It may improve the attritionresistance of the catalyst particle. The binder acts as For example, thebinder material may comprise alumina (such as amorphous alumina),silica-alumina (such as amorphous silica-alumina), or silica (such asamorphous silica). According to one or more embodiments, the bindermaterial may comprise pseudoboehmite. As used in this disclosure,“pseudoboehmite” refers to an aluminum-containing compound with thechemical composition AlO(OH) consisting of crystalline boehmite.Suitable pseudoboehmite includes CATAPAL® aluminas, commerciallyavailable from Sasol Limited of Johannesburg, South Africa. Boehmiterefers to aluminum oxide hydroxide as well, but pseudoboehmite generallyhas a greater amount of water than boehmite. The binder material, suchas pseudoboehmite, may be peptized with an acid, such as a mono-proticacid, such as nitric acid (“HNO₃”) or hydrochloric acid (“HCl”).

According to one or more embodiments, the cracking catalyst may comprisethe one or more binder materials in an amount of from 5 wt. % to 30 wt.% of the total cracking catalyst. For example, according to embodiments,the cracking catalyst may comprise binder material in an amount of from5 wt. % to 25 wt. % of the total cracking catalyst, from 5 wt. % to 20wt. % of the total cracking catalyst, from 5 wt. % to 15 wt. % of thetotal cracking catalyst, from 5 wt. % to 10 wt. % of the total crackingcatalyst, from 10 wt. % to 30 wt. % of the total cracking catalyst, from15 wt. % to 30 wt. % of the total cracking catalyst, 20 wt. % to 30 wt.% of the total cracking catalyst, or from 25 wt. % to 30 wt. % of thetotal cracking catalyst. According to additional embodiments, crackingcatalyst may comprise the binder materials in an amount of from 10 wt. %to 20 wt. % of the total cracking catalyst, such as from 12 wt. % to 18wt. % of the total cracking catalyst, or from 14 wt. % to 16 wt. % ofthe total cracking catalyst. It should be understood that, in one ormore embodiments, the cracking catalyst may include any single disclosedbinder material in an amount of the disclosed wt. % ranges. Inadditional embodiments, the cracking catalyst may include any two ormore binder materials in combination in an amount of the disclosed wt. %ranges.

In one or more embodiments, the catalyst composition may comprise one ormore matrix materials. As use in this disclosure, “matrix materials” mayrefer to a clay material such as kaolin. Without being bound by theory,it is believed that the matrix materials of an the catalyst serves bothphysical and catalytic functions. Physical functions include providingparticle integrity and attrition resistance, acting as a heat transfermedium, and providing a porous structure to allow diffusion ofhydrocarbons into and out of the catalyst microspheres. The matrix canalso affect catalyst selectivity, product quality and resistance topoisons. The matrix materials may tend to exert its strongest influenceon overall catalytic properties for those reactions which directlyinvolve relatively large molecules.

In one or more embodiments, the matrix material comprises kaolin. Asused in this disclosure, “kaolin” refers to a clay material that has arelatively large amount (such as at least about 50 wt. %, at least 60wt. %, at least 70 wt. %, at least 80 wt. %, at least 90 wt. %, or evenat least 95 wt. %) of kaolinite, which can be represented by thechemical formula Al₂Si₂O₅(OH)₄. Kaolin is sometimes referred to as“china clay.” In additional embodiments, the matrix material maycomprise other clay materials.

According to one or more embodiments, the cracking catalyst comprises ormore matrix materials in an amount of from 30 wt. % to 60 wt. % of thetotal cracking catalyst. For example, according to embodiments, thecracking catalyst may comprise the matrix material in an amount of from30 wt. % to 55 wt. % of the total cracking catalyst, from 30 wt. % to 50wt. % of the total cracking catalyst, from 30 wt. % to 45 wt. % of thetotal cracking catalyst, from 30 wt. % to 40 wt. % of the total crackingcatalyst, from 30 wt. % to 35 wt. % of the total cracking catalyst, from35 wt. % to 60 wt. % of the total cracking catalyst, from 40 wt. % to 60wt. % of the total cracking catalyst, from 45 wt. % to 60 wt. % of thetotal cracking catalyst, from 50 wt. % to 60 wt. % of the total crackingcatalyst, or from 55 wt. % to 60 wt. % of the total cracking catalyst.According to additional embodiments, the cracking catalyst may comprisethe matrix material in an amount of from 35 wt. % to 55 wt. % of thetotal cracking catalyst, such as from 40 wt. % to 50 wt. % of the totalcracking catalyst, or from 43 wt. % to 47 wt. % of the total crackingcatalyst. It should be understood that, in one or more embodiments, thecracking catalyst may include any single disclosed matrix material in anamount of the disclosed wt. % ranges. In additional embodiments, thecracking catalyst may include any two or more matrix materials incombination in an amount of the disclosed wt. % ranges.

As described in this disclosure, the cracking catalyst may be in theform of shaped microparticles, such as microspheres. As described,“microparticles” refer to particles having of size of from 0.1 micronsand 100 microns. The size of a microparticle refers to the maximumlength of a particle from one side to another, measured along thelongest distance of the microparticle. For example, a spherically shapedmicroparticle has a size equal to its diameter, or a rectangular prismshaped microparticle has a maximum length equal to the hypotenusestretching from opposite corners.

According to embodiments, the zeolites of the zeolite mixture (forexample, ZSM-5, zeolite Beta, and zeolite Y) may all be included in eachmicroparticle. However, in other embodiments, microparticles may bemixed, where the microparticles contain only a portion of the zeolitemixture. For example, a mixture of three microparticle types may beincluded in the cracking catalyst, where one type of microparticleincludes only ZSM-5, one type of microparticle includes only zeoliteBeta, and one microparticle type includes only zeolite Y.

The cracking catalyst may be formed by a variety of processes. Accordingto one embodiment, the matrix material may be mixed with a fluid such aswater to form a slurry, and the zeolites may be separately mixed with afluid such as water to form a slurry. The matrix material slurry and thezeolite slurry may be combined under stirring. Separately, anotherslurry may be formed by combining the binder material with a fluid suchas water. The binder slurry may then be combined with the slurrycontaining the zeolites and matrix material to form an all-ingredientsslurry. The all-ingredients slurry may be dried, for example byspraying, and then calcinated, to produce the microparticles of thecracking catalyst.

The cracking catalyst may be deactivated by contact with steam prior touse in a reactor to convert hydrocarbons. The purpose of steam treatmentis to accelerate the hydrothermal aging which occurs in an operationalFCC regenerator to obtain an equilibrium catalyst. Steam treatment maylead to the removal of aluminum from the framework leading to a decreasein the number of sites where framework hydrolysis can occur underhydrothermal and thermal conditions. This removal of aluminum results inan increased thermal and hydrothermal stability in dealuminatedzeolites. The unit cell size may decrease as a result of dealuminationsince the smaller SiO₄ tetrahedron replaces the larger AlO₄ ⁻tetrahedron. The acidity of zeolites may also affected by dealuminationthrough the removal of framework aluminum and the formation ofextra-framework aluminum species. Dealumination may affect the acidityof the zeolite by decreasing the total acidity and increasing the acidstrength of the zeolite. The total acidity may decrease because of theremoval of framework aluminum, which act as Bronsted acid sites. Theacid strength of the zeolite may be increased because of the removal ofpaired acid sites or the removal of the second coordinate next nearestneighbor aluminum. The increase in the acid strength may be caused bythe charge density on the proton of the OH group being highest whenthere is no framework aluminum in the second coordination sphere.

According to one or more embodiments, the hydrocarbon feed stream may becontacted by the cracking catalyst in a reactor unit. As used in thisdisclosure, a “reactor unit” refers to a vessel or series of vessels inwhich one or more chemical reactions may occur between one or morereactants in the presence of one or more catalysts. For example, areactor may include a tank or tubular reactor configured to operate as abatch reactor, a continuous stirred-tank reactor (CSTR), or a plug flowreactor. Example reactors include packed bed reactors such as fixed bedreactors, and fluidized bed reactors.

As depicted in FIG. 1, according to one or more embodiments, the reactorunit used to convert the hydrocarbon feed stream may be a fluidized bedreactor. As used in this disclosure, a “fluid catalytic crackingreactor” refers to a reactor unit that can be operable to contact afluidized reactant with a solid material (usually in particulate form),such as a cracking catalyst. As described in this disclosure, afluidized bed reactor which cracks a reactant stream with a fluidizedsolid cracking catalyst may be referred to as a fluid catalytic crackingreactor unit.

FIG. 1 schematically depicts a fluid catalytic cracking reactor unit 100which converts a hydrocarbon feed stream 110 into a product stream 120.The embodiment of FIG. 1 includes cracking catalyst regenerationfunctionality.

Still referring to FIG. 1, the hydrocarbon feed stream 110 may be passedto a fluid catalytic cracking reactor unit 100. The fluid catalyticcracking reactor unit 100 may include a cracking catalyst/feed mixingzone 132, a reaction zone 134, a separation zone 136, and a crackingcatalyst regeneration zone 138. The hydrocarbon feed stream 110 may beintroduced to the cracking catalyst/feed mixing zone 132 where it ismixed with regenerated cracking catalyst from regenerated catalyststream 140 passed from the cracking catalyst regeneration zone 138. Thehydrocarbon feed stream 110 is reacted by contact with the regeneratedcracking catalyst in the reaction zone 134, which cracks the contents ofthe hydrocarbon feed stream 110. Following the cracking reaction in thereaction zone 134, the contents of the reaction zone 134 are passed tothe separation zone 136 where the cracked product of the reaction zone134 is separated from spent catalyst, which is passed in a spentcatalyst stream 142 to the cracking catalyst regeneration zone 138 whereit is regenerated by, for example, removing coke from the spent crackingcatalyst. The product stream 120 is passed from the fluid catalyticcracking reactor unit, where it may be further processed, for example byseparation into multiple streams.

It should be understood that fluid catalytic cracking reactor unit 100of FIG. 1 is a simplified schematic of one particular embodiment of afluid catalytic cracking reactor unit, and other configurations of fluidcatalytic cracking reactor units may be suitable for the presentlydisclosed hydrocarbon cracking methods. For example, in someembodiments, the catalyst may not be recycled, and in such embodiments,the components of FIG. 1 related to the regeneration of the crackingcatalyst would not be present.

As referred to in this disclosure, the hydrocarbon feed stream is afluid stream (either gaseous or liquid) which has a relatively great APIgravity, such as at least 30 degrees, and often greater than 50 degrees.In some embodiments, the hydrocarbon feed stream 110 may have an APIgravity of at least about 30 degrees, at least 35 degrees, at least 40degrees, at least 45 degrees, at least 50 degrees, at least 55 degrees,or even at least 60 degrees.

The hydrocarbon feed stream 110 may be a crude oil feedstock, or may beprocessed in some way prior to being cracked. For example a relativelyheavy oil may be separated into two or more components to form thehydrocarbon feed stream 110. In some embodiments, the hydrocarbon feedstream 110 may be processed to remove components such as one or more ofmetals, sulfur, or nitrogen prior to being treated with the crackingcatalysts presently described. According to various embodiments, atleast 50 wt. %, 60 wt. %, 70 wt. %, 80 wt. %, 90 wt. %, 95 wt. %, oreven 99 wt. % of the hydrocarbon feed stream is crude oil such as gascondensate.

According to one or more embodiments, the hydrocarbon feed stream 110which is cracked consists of gas condensate, such as gas condensateavailable from the Khuff geological formation. Khuff gas condensateproperties, an example feedstock fuel for the cracking process of thepresent disclosure, is shown in Table 1. Additionally, FIG. 2 shows theboiling point profile for Khuff gas condensate. In FIG. 2, “IBP” refersto the initial boiling point and “FBP” refers to the final boilingpoint. FIG. 2 depicts weight percentages of oil boiled as a function ofincreasing temperature.

TABLE 1 Example of Khuff Gas Condensate Property Units Value AmericanPetroleum Institute degrees 52.8 (API) gravity Density grams per cubiccentimeter 0.7695 (g/cm³) Sulfur Content weight percent (wt. %) 0.03Nickel parts per billion by weight Less than 20 (ppbw) Vanadium ppbwLess than 20 Iron ppbw Less than 20 Copper ppbw Less than 20 SodiumChloride (NaCl) ppbw 50 Content Conradson Carbon wt. % 0.03 Basicnitrogen Parts per million (ppm) Less than 10

According to one or more embodiments, the hydrocarbon feed stream 110may have a boiling point profile as described by the 5 wt. % boilingtemperature, the 25 wt. % boiling temperature, the 50 wt. % boilingtemperature, the 75 wt. % boiling temperature, and the 95 wt. % boilingtemperature. These respective boiling temperatures correspond to thetemperature at which a given weight percentage of the hydrocarbon feedstream boils. In some embodiments, the hydrocarbon feed stream 100 mayhave one or more of a 5 wt. % boiling temperature of less than 150° C.,a 25 wt. % boiling temperature of less than 225° C., a 50 wt. % boilingtemperature of less than 300° C., a 75 wt. % boiling temperature of lessthan 400° C., and a 95 wt. % boiling temperature of less than 600° C.According to one or more embodiments, the hydrocarbon feed stream 100may have one or more of a 5 wt. % boiling temperature of from 0° C. to100° C., a 25 wt. % boiling temperature of from 75° C. to 175° C., a 50wt. % boiling temperature of from 150° C. to 250° C., a 75 wt. % boilingtemperature of from 250° C. to 350° C., and a 95 wt. % boilingtemperature of from 450° C. to 550° C.

According to one or more embodiments, the reaction fluid catalyticcracking reaction may be a high severity fluid catalytic crackingreaction. As used in this disclosure, “high severity” fluid catalyticcracking refers to cracking under reaction temperatures of at leastabout 500 degrees Celsius (“° C.”). According to one or moreembodiments, the reaction zone 134 of the fluid catalytic crackingreactor unit 100 may operate at a temperature of from 500° C. to 700°C., such as from about 600° C. to about 700° C., or from about 625° C.to about 675° C.

According to embodiments, the catalyst to oil weight ratio may be from 7to 10, such as from 7.5 to 9.5 or from 7.75 to 8.25. In one or moreembodiments, the residence time of the mixture in the reaction zone 127may be from 0.2 to 2 seconds.

According to one or more embodiments, the contacting of the hydrocarbonfeed stream 125 with the cracking catalyst produces a product stream 120that may comprise at least 20 wt. % of light olefins selected fromethylene, propylene, and butene. For example, in embodiments, theproduct stream 120 may comprise at least 22 wt. % of light olefins, atleast 25 wt. % of light olefins, at least 30 wt. % of light olefins, oreven at least at least 40 wt. % of light olefins. In additionalembodiments, the product stream 120 may comprise at least 3 wt. % ofethylene, at least 5 wt. % of ethylene, at least 7 wt. % of ethylene, oreven at least 8 wt. % of ethylene, at least 13 wt. % of propylene, atleast 15 wt. % of propylene, at least 19 wt. % of propylene, or even atleast 21 wt. % of propylene, at least 8 wt. % of butene, at least 10 wt.% of butene, at least 14 wt. % of butene, or even at least 18 wt. % ofbutene.

EXAMPLES

The various embodiments of methods and systems for cracking hydrocarbonfeed streams will be further clarified by the following examples. Theexamples are illustrative in nature, and should not be understood tolimit the subject matter of the present disclosure.

Example 1—Cracking Catalyst Preparation

A number of cracking catalysts were prepared with varying amounts ofZSM-5, zeolite Y, and zeolite Beta. Additionally, comparative catalystswere prepared under the same procedures. The catalyst compositionsprepared are show in Tables 2. Additionally, comparative catalystcompositions were prepared and are shown in Table 3. It is noted thatSample 2 was prepared from microspheres of Comparative Sample A (25 wt.%), Comparative Sample B (15 wt. %), and Comparative Sample C (60 wt.%). The ZSM-5 zeolite used was CBV 2314 zeolite commercially availablefrom Zeolyst International, which has a silica to alumina ratio of 23.The zeolite Beta used was CP814E zeolite commercially available fromZeolyst International, which has a silica to alumina ratio of 25. Thezeolite Y used was SP13-0159 zeolite commercially available from W.R.Grace and Company, which had a silica to alumina ratio of 6.

TABLE 2 Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 wt. % Kaolin 45 4535 35 35 wt. % Alumina 15 15 15 15 15 wt. % ZSM-5 10 10 10 10 10 wt. %zeolite 10 6 30 20 10 Beta wt. % zeolite Y 20 24 10 20 30

TABLE 3 Comparative Comparative Comparative Comparative Sample A SampleB Sample C Sample D wt. % Kaolin 45 45 45 45 wt. % Alumina 15 15 15 15wt. % ZSM-5 0 0 40 10 wt. % zeolite 0 40 0 30 Beta wt. % zeolite Y 40 00 0

To prepare the catalysts, first, ZSM-5, zeolite Y, and zeolite Beta wereimpregnated with phosphorus. The targeted phosphorus content was 3.5 wt.% P₂O₅ of the total cracking catalyst weight.

The catalysts were prepared by blending kaolin clay powder withde-ionized water. In a separate step, the zeolite mixture (dry basis)was made into a slurry with de-ionized water. While stirring the zeoliteslurry, an appropriate amount of ortho-phosphoric acid (concentration 85wt %) was gradually added to achieve 3.5 wt. % of total zeolite weight.Stirring was continued for another 15 minutes. The zeolite-phosphoricacid slurry was then added to the kaolin slurry and stirred for 5minutes.

Separately, a slurry of Catapal alumina was prepared by mixing Catapalalumina (dry basis) with distilled water, which was peptized by addingan appropriate amount of concentrated nitric acid (concentration of 70wt. %) and stirring for thirty minutes. The resulting peptized Catapalslurry was added to the zeolite-kaolin slurry and blended for 10minutes, producing a slurry with high viscosity where the individualparticles remain suspended.

The resulting slurry was made up of 30 wt. % solids was spray dried toproduce particles of 20-100 microns. The dried particles were thencalcined at 500° C. for 3 hours.

Example 2—Catalytic Testing

Catalytic cracking of Khuff Gas Condensate (composition shown inTable 1) was carried out in a fixed-bed microactivity testing unit(“MAT”) unit, manufactured by Sakuragi Rikagaku of Japan, according toASTM D-3907 and D-5154 testing protocols. For each MAT run, a full massbalance was obtained and was found to be around 100%. All MAT runs wereperformed at a cracking temperature of 650° C. and a time-on-stream of30 seconds. All samples were steamed at 750° C. for 3 hours prior toexperimentation.

Data related to the catalytic activity of the catalyst formulations ofTables 2 and 3 are provided in Tables 4 and 5, respectively. For thepurpose of assessing the catalyst performance on conversion of lightfractions (that is, those with hydrocarbons of 5 or less carbonmolecules), is defined as the total weight percent of gas products andcoke for the cracking of Arab Extra Light Crude fractions. “CONV. (wt.%)” in Tables 4 and 5 is the total dry gas, LPG and coke formed.

TABLE 4 Sample Sample 1 Sample 2 3 Sample 4 Sample 5 catalyst to oil 8 88.02 9.23 8.34 ratio by weight CONV. (wt %) 60 59 62.33 62.61 64.95Yields ethylene 5 7 7.99 7.65 7.46 propylene 13 19 15.39 11.98 12.17butene 6 11 7.84 5.37 5.65 Groups (wt. %) H₂—C₂ (dry gas) 15 15 20.9125.46 25.43 C₃—C₄ (LPG) 40 41 40.54 36.15 38.6 C₂ = −C₄ = 25 36 31.22 2525.28 (light olefins) Gasoline 34 28 28.3 26.06 26.8 Coke 5.1 3.9 0.881.01 0.91

TABLE 5 Comparative Comparative Comparative Comparative Sample A SampleB Sample C Sample D catalyst to oil 8 8 8.33 8 ratio by weight CONV. (wt%) 68 59 52.93 46 Yields ethylene 5 7 9.54 4 propylene 9 17 15.78 16butene 4 9 8.49 11 Groups (wt %) H₂—C₂ (dry 21 16 20.45 8 gas) C₃—C₄(LPG) 36 41 31.61 30 C₂ = −C₄ = 18 33 33.81 27 (light olefins) Gasoline28 33 34.48 45 Coke 11.3 2.4 0.87 0.8

The results show the effect of zeolite Beta on conversion and the yieldof light olefins. Conversion and light olefin yield increase with theamount of zeolite Beta in the formulation. The results also show thesynergetic effect of having zeolite Y, zeolite Beta and ZSM-5 in theformulation as improved light olefin yield is realized than when justonly either ZSM-5 or zeolite Y are in the formulation. Therefore it maybe advantageous to supplement the conventional FCC catalyst with zeolitebeta in order to increase the light olefin yield and gasoline octane.Having a catalyst formulation containing a large pore zeolite, such aszeolite Y or zeolite Beta, as the primary cracking component and amedium pore zeolite such as ZSM-5 provides a more active catalyst withbetter light olefin yield.

It is noted that one or more of the following claims utilize the term“where” as a transitional phrase. For the purposes of defining thepresent technology, it is noted that this term is introduced in theclaims as an open-ended transitional phrase that is used to introduce arecitation of a series of characteristics of the structure and should beinterpreted in like manner as the more commonly used open-ended preambleterm “comprising.”

It should be understood that any two quantitative values assigned to aproperty may constitute a range of that property, and all combinationsof ranges formed from all stated quantitative values of a given propertyare contemplated in this disclosure.

Having described the subject matter of the present disclosure in detailand by reference to specific embodiments, it is noted that the variousdetails described in this disclosure should not be taken to imply thatthese details relate to elements that are essential components of thevarious embodiments described in this disclosure, even in cases where aparticular element is illustrated in each of the drawings that accompanythe present description. Rather, the claims appended hereto should betaken as the sole representation of the breadth of the presentdisclosure and the corresponding scope of the various embodimentsdescribed in this disclosure. Further, it will be apparent thatmodifications and variations are possible without departing from thescope of the appended claims.

According to a first aspect of the present disclosure, a method forcracking a hydrocarbon feed stream may comprise contacting thehydrocarbon feed stream with a cracking catalyst in a reactor unit,where the hydrocarbon feed stream has an API gravity of at least 40degrees, and where the cracking catalyst comprises: one or more bindermaterials in an amount of from 5 wt. % to 30 wt. % of the total crackingcatalyst; one or more matrix materials in an amount of from 30 wt. % to60 wt. % of the total cracking catalyst; *BEA framework type zeolite inan amount of from 5 wt. % to 45 wt. % of the total cracking catalyst;FAI framework type zeolite in an amount of from 5 wt. % to 45 wt. % ofthe total cracking catalyst; and MFI framework type zeolite in an amountof from 5 wt. % to 45 wt. % of the total cracking catalyst.

A second aspect of the present disclosure may include the first aspect,where the hydrocarbon feed stream has an API gravity of from 45 degreesto 60 degrees.

A third aspect of the present disclosure may includes the first orsecond aspects, where at least 95 wt. % of the hydrocarbon feed streamis crude oil.

A fourth aspect of the present disclosure may include any of the firstthrough third aspects, where the reactor unit is a fluidized bedreactor.

A fifth aspect of the present disclosure may include any of the firstthrough fourth aspects, where the amount of the FAU framework typezeolite is from 10 wt. % to 20 wt. % of the total cracking catalyst.

A sixth aspect of the present disclosure may include any of the firstthrough fifth aspects, where the amount of the MFI framework typezeolite is from 10 wt. % to 20 wt. % of the total cracking catalyst.

A seventh aspect of the present disclosure may include any of the firstthrough sixth aspects, where one or more of the MFI framework typezeolite, *BEA framework type zeolite, and FAU framework type zeolitecomprise phosphorous pentoxide.

An eighth aspect of the present disclosure may include the seventhaspect, where one or more of the MFI framework type zeolite, *BEAframework type zeolite, and FAU framework type zeolite comprise from 1wt. % to 20 wt. % of phosphorous pentoxide.

A ninth aspect of the present disclosure may include any of the firstthrough eighth aspects, where at least one of the one or more bindermaterials is pseudoboehmite.

A tenth aspect of the present disclosure may include any of the firstthrough ninth aspects, where the cracking catalyst comprises from 5 wt.% to 30 wt. % of pseudoboehmite.

An eleventh aspect of the present disclosure may include any of thefirst through tenth aspects, where the amount of the one or more bindermaterials is from 10 wt. % to 20 wt. % of the total cracking catalyst.

A twelfth aspect of the present disclosure may include any of the firstthrough eleventh aspects, where one or more of the binders is kaolin.

A thirteenth aspect of the present disclosure may include any of thefirst through twelfth aspects, where cracking catalyst comprises the oneor more binder materials in an amount of from 30 wt. % to 50 wt. % ofthe total cracking catalyst.

A fourteenth aspect of the present disclosure may include any of thefirst through thirteenth aspects, where the catalyst to oil weight ratiois from 7 to 10.

A fifteenth aspect of the present disclosure may include any of thefirst through fourteenth aspects, where the MFI framework type zeolitecomprises ZSM-5.

A sixteenth aspect of the present disclosure may include any of thefirst through the fifteenth aspects, where the FAU framework typezeolite comprise zeolite Y.

A seventeenth aspect of the present disclosure may include any of thefirst through the sixteenth aspects, where the *BEA framework typezeolite comprises zeolite Beta.

An eighteenth aspect of the present disclosure may include any of thefirst through the seventeenth aspects, where the contacting of thehydrocarbon feed stream with the cracking catalyst produces a productstream comprising at least 20 wt. % of light olefins selected fromethylene, propylene, and butene.

According to a nineteenth aspect of the present disclosure, a method forcracking a hydrocarbon feed stream may comprise contacting thehydrocarbon feed stream with a cracking catalyst in a reactor unit,where the hydrocarbon feed stream has an API gravity of at least 40degrees, and where the cracking catalyst comprises: pseudoboehmite in anamount of from 5 wt. % to 30 wt. % of the total cracking catalyst;kaolin in an amount of from 30 wt. % to 60 wt. % of the total crackingcatalyst; zeolite Beta in an amount of from 5 wt. % to 45 wt. % of thetotal cracking catalyst; zeolite Y in an amount of from 5 wt. % to 45wt. % of the total cracking catalyst; and ZSM-5 in an amount of from 5wt. % to 45 wt. % of the total cracking catalyst.

A twentieth aspect of the present disclosure may include the nineteenthaspect, where the hydrocarbon feed stream is a crude oil feedstock.

A twenty-first aspect of the present disclosure may include thenineteenth or twentieth aspects, where the hydrocarbon feed stream isgas condensate.

A twenty-second aspect of the present disclosure may include any of thenineteenth through the twenty-first aspects, where the reactor unit is afluidized bed reactor.

A twenty-third aspect of the present disclosure may include any of thenineteenth through twenty-second aspects, where one or more of theZSM-5, zeolite Beta, and zeolite Y comprise phosphorous pentoxide.

According to a twenty-fourth aspect of the present disclosure, a systemfor cracking a hydrocarbon feed stream may comprise a reactor; ahydrocarbon feed stream entering the reactor, where the hydrocarbon feedstream has an API gravity of at least 40 degrees; a product streamexiting the reactor; and a cracking catalyst positioned at least in thereactor, where the cracking catalyst comprises: one or more bindermaterials in an amount of from 5 wt. % to 30 wt. % of the total crackingcatalyst; one or more matrix materials in an amount of from 30 wt. % to60 wt. % of the total cracking catalyst; *BEA framework type zeolite inan mount of from 5 wt. % to 45 wt. % of the total cracking catalyst; FAUframework type zeolite in an amount of from 5 wt. % to 45 wt. % of thetotal cracking catalyst; FAU framework type zeolite in an mount of from5 wt. % to 45 wt. % of the total cracking catalyst; and MFI frameworktype zeolite in an amount of from 5 wt. % to 45 wt. % of the totalcracking catalyst.

A twenty-fifth aspect of the present disclosure may include thetwenty-fourth aspect, where the hydrocarbon feed stream has an APIgravity of from 45 degrees to 60 degrees.

A twenty-sixth aspect of the present disclosure may include thetwenty-fourth aspect or the twenty-fifth aspect, where at least 95 wt. %of the hydrocarbon feed stream is crude oil.

A twenty-seventh aspect of the present disclosure may include any of thetwenty-fourth through twenty-sixth aspects, where the reactor unit is afluidized bed reactor.

A twenty-eighth aspect of the present disclosure may include any of thetwenty-fourth through twenty-seventh aspects, where the amount of theFAU framework type zeolite is from 10 wt. % to 20 wt. % of the totalcracking catalyst.

A twenty-ninth aspect of the present disclosure may include any of thetwenty-fourth through twenty-eighth aspects, where the amount of the MFIframework type zeolite is from 10 wt. % to 20 wt. % of the totalcracking catalyst.

A thirtieth aspect of the present disclosure may include any of thetwenty-fourth through twenty-ninth aspects, where one or more of the MFIframework type zeolite, *BEA framework type zeolite, and FAU frameworktype zeolite comprise phosphorous pentoxide.

A thirty-first aspect of the present disclosure may include any of thetwenty-fourth through thirtieth aspects, where one or more of the MFIframework type zeolite, *BEA framework type zeolite, and FAU frameworktype zeolite comprise from 1 wt. % to 20 wt. % of phosphorous pentoxide.

A thirty-second aspect of the present disclosure may include any of thetwenty-fourth through thirty-first aspects, where at least one of theone or more binder materials is pseudoboehmite.

A thirty-third aspect of the present disclosure may include any of thetwenty-fourth through thirty-second aspects, where the cracking catalystcomprises from 5 wt. % to 30 wt. % of pseudoboehmite.

A thirty-fourth aspect of the present disclosure may include any of thetwenty-fourth through thirty-third aspects, where the amount of the oneor more binder materials is from 10 wt. % to 20 wt. % of the totalcracking catalyst.

A thirty-fifth aspect of the present disclosure may include any of thetwenty-fourth through thirty-fourth aspects, where one or more of thebinders is kaolin.

A thirty-sixth aspect of the present disclosure may include any of thetwenty-fourth through thirty-fifth aspects, where cracking catalystcomprises the one or more binder materials in an amount of from 30 wt. %to 50 wt. % of the total cracking catalyst.

A thirty-seventh aspect of the present disclosure may include any of thetwenty-fourth through thirty-sixth aspects, where the catalyst to oilweight ratio is from 7 to 10.

A thirty-eighth aspect of the present disclosure may include any of thetwenty-fourth through thirty-seventh aspects, where the MFI frameworktype zeolite comprises ZSM-5.

A thirty-ninth aspect of the present disclosure may include any of thetwenty-fourth through thirty-eighth aspects, where the FAU frameworktype zeolite comprise zeolite Y.

A fortieth aspect of the present disclosure may include any of thetwenty-fourth through thirty-ninth aspects, where the *BEA frameworktype zeolite comprises zeolite Beta.

What is claimed is:
 1. A method for cracking a hydrocarbon feed stream,the method comprising: contacting the hydrocarbon feed stream with acracking catalyst in a reactor unit, where the hydrocarbon feed streamhas an API gravity of at least 40 degrees, and where the crackingcatalyst comprises: one or more binder materials in an amount of from 5wt. % to 30 wt. % of the cracking catalyst; one or more matrix materialsin an amount of from 30 wt. % to 60 wt. % of the cracking catalyst; *BEAframework zeolite in an amount of from 5 wt. % to 30 wt. % of thecracking catalyst; FAU framework zeolite in an amount of from 5 wt. % to45 wt. % of the cracking catalyst; MFI framework zeolite in an amount offrom 5 wt. % to 45 wt. % of the cracking catalyst; and where the *BEAframework zeolite comprises less than 0.5 wt. % of transition metal. 2.The method of claim 1, where the hydrocarbon feed stream has an APIgravity of from 45 degrees to 60 degrees.
 3. The method of claim 1,where the amount of the FAU framework zeolite is from 10 wt. % to 20 wt.% of the total cracking catalyst.
 4. The method of claim 1, where theamount of the MFI framework zeolite is from 10 wt. % to 20 wt. % of thetotal cracking catalyst.
 5. The method of claim 1, where one or more ofthe MFI framework zeolite, *BEA framework zeolite, and FAU frameworkzeolite comprise phosphorus pentoxide.
 6. The method of claim 1, whereat least one of the one or more binder materials is pseudoboehmite. 7.The method of claim 1, where the amount of the one or more bindermaterials is from 10 wt. % to 20 wt. % of the cracking catalyst.
 8. Themethod of claim 1, where one or more of the matrix materials is kaolin.9. The method of claim 1, where cracking catalyst comprises the one ormore matrix materials in an amount of from 30 wt. % to 50 wt. % of thecracking catalyst.
 10. The method of claim 1, where the catalyst to oilweight ratio is from 7 to
 10. 11. The method of claim 1, where the MFIframework zeolite comprises ZSM-5.
 12. The method of claim 1, where theFAU framework zeolite comprise zeolite Y.
 13. The method of claim 1,where the *BEA framework zeolite comprises zeolite Beta.
 14. The methodof claim 1, where the contacting of the hydrocarbon feed stream with thecracking catalyst produces a product stream comprising at least 20 wt. %of light olefins selected from ethylene, propylene, and butene.
 15. Themethod of claim 1, where the hydrocarbon feed stream is gas condensate.16. The method of claim 1, where the hydrocarbon feed stream has a 5 wt.% boiling temperature of from 0° C. to 100° C., a 25 wt. % boilingtemperature of from 75° C. to 175° C., a 50 wt. % boiling temperature offrom 150° C. to 250° C., a 75 wt. % boiling temperature of from 250° C.to 350° C., and a 95 wt. % boiling temperature of from 450° C. to 550°C.
 17. The method of claim 1, where the FAU framework zeolite comprisesless than 1 wt. % of transition metal.
 18. The method of claim 1, wherethe MFI framework zeolite comprises less than 1 wt. % of transitionmetal.
 19. The method of claim 1, where the *BEA framework zeolitecomprises less than or equal to 0.1 wt. % of transition metal.